Aluminium repair - Surface finish

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Im wondering if there are any tricks to repairing aluminium (for example TIG weld a hole closed) and then to grind/treat the surface to resemble standard plate aluminum surface finish.My question is specifically on the surface refinishing, not TIG vs MIG etc.Any tricks or suggestions?Thanks
Reply:Hmm well good penetration and rod choice for base metal, weld, grind then blend, I am not aware of any secretsMillermatic 211Miller Syncrowave 350lx with cooler and tigrunner Thermal Dynamics cutmaster 811955 National Cylinder Gas O/A setup with original patina
Reply:Well if it is wrought, then best match may be 5356. If it is cast then 4000 series or 356/357.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Use a flap wheel to get it flush, and use a stainless steel brush to dull it up to make it less noticeable. What ill do sometimes is after its all ground flush and pretty I will use a die grinder and a wire wheel slowed down, dip the wheel into my green cutting wax and polish it up, works great for me. Some people use a scotch brite pad on an angle grinder. INothing Ever Got Done By Quitting, Never Give Up.
Reply:I find flap wheels are more likely to gouge the surface, using a flat sanding disc on an angle grinder can blend better, 60 then 80gr then 60 grit on a random orbit. should be quite flat after that. The stainless wire brush can re-grain and blend a bit. There is a Walter blending flap wheel with scotchbrite layered with fine sandpaper, works nicely on Aluminium and SS but not cheap.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:Originally Posted by pbiebachTIG weld a hole closed
Reply:I haven't tried the SS backing. It's kind of the opposite of Copper backing. Retaining heat instead of dissipating it. Anyone tried this?I do notice in a production run that copper backing gets smokin' hot, almost simultaneous heat sink and pre-heat.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:Can you show a pic of the finish your trying to match?I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Some good suggestions,Specifically I am trying to fill a hole in 1/8" sheet. (holes on an Aluminium boat console) I realize its probably impossible to match the finish perfectly, just trying to make it match as best I can.I gues
Reply:Bead blasting or light sandblasting?  S/F....Ken M
Reply:Weld the holes. Then use wood blocks with varying grades of sandpaper wrapped around them. Start at 220, work your way to 800. Hit the whole panel up with 1000 grit freehand. It will polish up pretty well.
Reply:Figure out how the metal is finished then seek to imitate it. Most sheet I buy has a parallel super fine finish, I guess the factory finish is done with an abrasive compound and cloth wheel. I can't think of a good small hand held machine to imitate this. I expect you'll have to use rubbing compound or jeweler's rouge, and a folded cloth.
Reply:Belt sander with 100-180. 220 is finer than most aluminum finishes. If it's mirror polish, I'd probably take the whole thing down to 180. Quicker than f#$%ing mirror polish!SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:Sand down to 180-220 grit then use steel wool in one direction to duplicate the grain.Last edited by M J D; 08-02-2014 at 01:31 PM.Reason: not finished